Apparatus for gaseous reduction of iron ore



E. RAMSAY ET AL APPARATUS FOR GASEOUS REDUCTION OF IRON Filed July l0, 1950 Aug. 11,` 1953 4 Sheets-Sheet l Aug. 11, 1953 E. RAMSAY ET AL APPARATUS FOR GASEOUS REDUCTION OF' IRUN ORE 4 Sheets-Sheet 2 Filed July lO, 1950 f f f l l 1 f l 1 IN1/E. TOR

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APPARATUS FOR GASEOUS REDUCTION OF' IRON ORE Filed July l0, 1950 4 Sheets-Sheet 5 (SMM /Y AS l R l l n I u l Ehi I N V EN T0125 'JA///V 496707597 BY Kaefer r 51965)/ Aug. l1, 1953 E. RAMsAY ET AL APPARATUS FOR GASEOUS REDUCTION OF' IRON ORE Filed July 1o, 195o 4 Sheets-Sheet 4 IN V EN TOR5 fA//NE Patented Aug. 11, 1953 APPARATUS FOR GASEOUS REDUCTION 0F IRON ORE Erskine Ramsay and Robert T.Bagby, Birmingham, Ala.

Application July 10, 1950, Serial No.v172,8 7r6 (Cl. 26S-24) 8 Claims. l

This invention relates to apparatus for the gaseous reduction of iron ore and has for an object the provision of such apparatus wherein theore in a finely divided state is partially reducedby a gaseous reducing agent as the ore and reducing agent pass through a rotary converter. Another object is to provide apparatus for gaseous reduction of iron ore in which a hydrocarbon gas and the ore are introduced into a r0- tating restricted spiral passage under heat and pressure and in such manner that the ore builds up in the bottom of the passage thus blocking the same, and is then blown out by the gas thereby producing a violent, turbulent mixture of the ore and gas and bringing the ore into intimate -contact with the reducing gas, eiecting partial reduction by a continuous process.

A still further object of our invention is to provide apparatus for the gaseous reduction of iron ore including a heated rotary converter having a restricted spiral path therein through which the ore passes being partially blown .through by the replacing gas at a high temperature and pressure, and otherwise falling down the passage as it is raised in the rotation of the chamber.

A still further object is to provide apparatus of Vthe character designated in which the hydrogen partially reduces the ore and the carbon of the gas is precipitated in the voids of the partially reduced ore and is conveyed with the ore to a reverberatcry furnace where complete reduction takes place.

A still further object of our invention is to provide apparatus of the character designated in which the ore .is pre-heated by the spent gases from the rotary converter.

Brieiiy our improved apparatus comprises means for introducing nely divided pre-heated ore and natural gas under pressure into an elongated rotary converter which has incorporated therein a restricted spiral passage. The converter rotates in a combustion chamber which is kept at a temperature sucient to cause a dissociation of the hydrocarbon gas into hydrogen and carbon, but not high enough to cause the carbon to reduce the ore. As the ore and the decomposed hydrocarbon gases pass through the rotary converter the ore falls by gravity into the lower portion thereof thus momentarily blocking the passage in the spiral passage. The incoming gas under pressure then blows out the ore forming the block, thus providing violence in the conveyor and bringing the ore into intimate' contact with the hydrogen gas which partially reduces the ore. This building up and blowing out ofthe ore from the lower portion of the rotating converter also increases the back pressure in the converter. The carbon is precipitated in the voids of the ore and is conveyed with the partially reduced ore to a reverberatory furnace Where reduction is completed. Most of the hydrogen is used in the partial reduction of the ore in the rotary converter. The remaining hydrogen is separated `from the ore and is returned to a second combustion chamber which .pre-heats the ore as it is conveyed toward the entrance of the rotary. converter.

Apparatus embodying features of our invention is illustrated in the accompanying drawings forming a part of this application in which:

Fig. 1 is a sectional view taken along line I-I 0f Fig. 2;

Fig. 2 is a sectional View taken along line II-II of Fig. l;

Fig. 3 is a sectional view taken along line III- III of Fig. l;

Fig. 4 is a plan view taken along line IV-IV of Fig. 2;

Fig. 5 is a view taken along line V-V of Fig. 2;

Fig. 6 is a diagrammatic plan view of the rotary converters communicating with a reverberatory furnace; and

Fig. 7 is an enlarged sectional view of the means for introducing the ore and gas into the rotary converter.

Referring now to the drawings for a better understanding of our invention, we show two rotary converters A and B mounted on a foundation iii. A suitable shelter l I is provided overthe converters. For convenience of description, throughout this specification and the claims, the forward portion of the apparatus will be that portion cf the apparatus for receiving the ore to be reduced. Also, since the apparatus and oper- J ation of fboth converters is the same, the description and method of operation of only one converter will be given herein.

Each rotary converter is rotatably mounted in a combustion chamber I2 lined with iire brick Si and having heating elements lei in the lower portion thereof which may be gas burners or other suitable heating means. The converter comprises an elongated outer cylinder I6 having a central flue or cylindrical passage I1 extending therethrough and having a somewhat restricted elongated spiral passage I8 extending from end to end thereof and surrounding the flue I1. The spiral passage I8 is formed by a continuous spiral flight I 9 which connects the outer cylinder I6 and the inner cylinder or flue I1. The converter is rotatably mounted in suitable bearings 2I at the forward end and bearingsl 22 at the rear end thereof and is rotated by any suitable means such as by a sprocket 23 and a drive chain 24 connected to a suitable lsource of power such as an electric motor 26. Reducing gears 21 are provided to reduce the speed so that the converter rotates at 1/3 revolution per minute. Adjacent the rear end of the converter is a smoke stack 28 communicating with the flue I1 by means of a sleeve 29 at the forward side of the smoke stack. The sleeve 29 extends forwardly and slida'bly ts within the rear end of the flue I1. The flue I1 is provided with a plurality of radial conduits 3| adjacent the forward end thereof through which the hot gases of combustion pass from the combustion chamber I2 to the flue I1. Immediately forward of the radial openings 3| is a plate 32 which extends across the flue I1 and seals the same forward of the radial conduits 3 I. The products of combustion pass from the combustion chamber I2 through the radial conduits 3| into the longitudinal extending flue I1 thence out through the smoke stack 28 to the atmosphere. The space dened between the cylinder I6 and the re brick I3 of the combustion chamber provides a passage through which the produ-cts of combustion pass and heat the outer walls of the converter. As shown in Eig. 5 the forward end of the converter is provided with a plurality of longitudinally extending conduits 33 located between the radial openings 3l for passing ore 34 to be reduced and a hydrocarbon gas into the forward end of the spiral passage I8. Immediately forward of the spiral passage I8 is an outer cylinder 35 and an inner concentric cylinder 36 defining between them an annular space 31, which communicates with the conduits 33. The cylinder 36 may be a continuation of flue I1. The outer cylinder 35 also serves as a journal for the forward end of the converter in bearings 2|. As shown in Fig. '1 the forward ends of the cylinders 35 and 35 are bent outwardly to form an annular opening 38 which opens outwardly with respect to the longitudinal axis of the converter. Slidably fitting over the opening 38 is a cylindrical sleeve mem- 'ber 39. The sleeve member 39 is held in place and a sealed joint is formed with the outer edges of the cylinders 35 and 36 by means of annular metal strips 40 dove-tailed in cross section which ts in cylindrical recesses 4I formed in the joining members. Communicating with the opening 38 is a pipe 42 which is secured to the top of the sleeve member 39. The hydrocarbon gas is introduced into the pipe 42 through a pipe 43 having a regulating valve 44 therein. Mounted above the pipe 42 is a hopper 45 having a rotary pressure sealed feeder 46 in the bottom thereof. The hopper 45 is divided adjacent the lower portion thereof to compensate for expansion and is provided with means whereby the bottom section 41 of the hopper will move relative to the top section 41' without forming a gap between the two sections.

At the rear end of the converter the outer cylinder I6 slopes inwardly as at 48 and then rearwardly parallel to and spaced from the flue I1 to form a journal for the rear end of the converter in bearings 22. The rear ends of cylinder I6 and flue I1 are bent outwardly in the same manner as the forward ends of cylinders 35 and 36 to form an annular opening 49 which also opens outwardly with respect to the longitudinal axis of the converter. A cylindrical sleeve member El slidably ts over the opening 49. One end of a pipe 52 for conveying the partially reduced ore and spent gases from the converter communicates with the opening 49 and is secured to the sleeve 5I at the top thereof. The other end of the pipe 52 is tapered as at 53 to approximately one half the diameter of pipe 52 to create a back pressure in the converter and is connected to the inlet side of a cyclone separator 54 where the gas is separated from the ore. A pipe 56, connected to the bottom of the separator 54 conveys the partially reduced ore to a reverberatory furnace 51 where complete reduction of the ore takes place in a manner well understood.

A pipe 58 connected to the outlet side of the separator 54 conveys the spent gases to a second combustion chamber 5S located above the combustion chamber I2. Mounted on and extending across the combustion chamber 59 is a metal plate 6I, said plate extends upwardly at the rear end thereof to receive the ore to be preheated from a crushing plant not shown. The forward end of the plate 6I joins the upper adjacent edge of the hopper 45. The gas is burned in the forward portion of the -chamber 59 by suitable burners 52 and the products of combustion are deflected through the chamber 59 by means of baffles 53 and thence out through a stack 64 to the atmosphere. Rotatably mounted, on shafts 55, above the forward and rear ends of the chamber 59 are sprockets 66 for driving an ore conveyor 61 comprising a plurality of angles 68 secured to endless chains 69. As the chains rotate clockwise the lower edges of the angles 58 contact the plate 6i as they pass thereover and move the ore 34 toward the hopper 45. The plate 6I transfers the heat from the chamber 59 to the ore as it passes thereover.

From the foregoing the operation of our improved apparatus for reducing iron ore will be readily understood. The ore in a finely divided state is fed onto the rear portion of plate 6I and is conveyed across said plate 6I by the conveyor 51 thereby pre-heating the ore to approximately 600 F. The pre-heated ore falls into the hopper 45 and is fed through the rotary feeder 46 into pipe 42. A hydrocarbon gas such as natural gas is also introduced into the pipe 42 at a pressure of from 300 to 400 pounds per square inch. The pressure sealed rotary feeder 46 prevents the ore from being blown upwardly into the hopper by the pressure in pipe 42. The preheated ore and hydrocarbon gas passes through the conduits 33 and is forced by the gas pressure into the spiral passage I8, the converter rotating in a direction to cause the ore to move toward the rear end thereof. As the converter rotates the ore falls by gravity into the lower portion of the restricted spiral passage and thus blocking it momentarily. The incoming gases under pressure then blow out the ore block thereby bringing the ore into intimate contact with the reducing gas. As the ore and hydrocarbon gas passes through the spiral passage I8 it is heated to a temperature of from 1400 to 1800 F. by burning natural gas 5A in the combustionchamber l 2 as describedv above; The hydrocarbonl gas at this temperaturel decomposes into hydrogenand carbon. The carbon is precipitated in the voids of the ore while the hydrogen partially reduces the ore asit passes through the spiral passage I0. The ore containing the carbon and the unused hydrogen gas passes through pipe 52v thence through the tapered portion to the-separator 54A. In the'separator 5d the gases areseparated from the ore and carbon and returned to the combustion chamber 5e for preheating the ore. The ore and carbon pass'from the separator 54 into the reverberatory furnace 5l Where complete reduction of the ore takes place.

In the operation of our apparatus for reducing iron ore, we have found that approximately 10,000 cubic feet of natural gas, at standard temperature and pressure, per ton of ore is required in the rotary converter to be decomposed into hydrogen and carbon. This amount of gas reduces approximately one-third of the oxygen with the hydrogen and provides approximately 310 pounds of carbon in the voids of the ore for completing the reduction of the ore in the re- Verberatory furnace. Approximately 10,000 cubic feet of gas, at standard temperature and pressure, per ton of ore is required to heat the rotary converter; and approximately 10,000 cubic feet of gas, at standard conditions, per ton of ore is required to complete the reduction of the ore in the reverberatory furnace, thus making a total of 30,000 cubic feet of natural gas for complete reduction of one ton of ore. We have also found that approximately 90% of the heat value of the hydrogen gas is used in the rotary converter to partially reduce the ore. The spent gases are used to preheat the ore as described above thus utilizing practically all of the fuel value of the hydrogen gas.

From the foregoing it will be apparent that we have devised improved apparatus for reducing iron ore with a hydrocarbon gas. By providing apparatus whereby the ore is reduced continuousiy and practically all of the heat value of the reducing gases is utilized, the iron ore is reduced more economically.

While we have shown our invention in but one form, it will be obvious to those skilled in the art that it is not so limited, but is susceptible of various changes and modifications without departing from the spirit thereof, and we desire therefore, that only such limitations shall be placed thereupon as are specically set forth in the appended claims.

What we claim is:

l. Apparatus for partial gaseous reduction of iron ore comprising a heating chamber, a reducing chamber having a restricted annular spiral opening therethrough dei-ined by inner and outer cylindrical walls and rotatably mounted in the heating chamber, a centrally disposed opening along the longitudinal axis of the reducing chamber defined by said inner cylindrical wall, means to introduce continuously the ore to be reduced and a hydrocarbon gas into the forward end of said spiral opening under pressure, means communicating said heating chamber with one end of said centrally disposed opening, there being an outlet at the other end of said centrally disposed opening and means in said heating chamber to heat indirectly said ore and gas as the same passes through the spiral opening to a temperature to cause a dissociation of the gas into hydrogeny and carbon and cause the hydrogen to partially reduce the ore.

2. Apparatus for partial gaseous reduction of? bustion chamber, there being a, centrally disposed flue through said converter defined by said inner cylindrical wall, a plate-sealing the forward' end of said fluev and a smoke stackv at the rear' end thereof, there ybeing openings at the forward end of said flue communicating said flue with the combustion chamber, there being a spiral passageway through said converter between said inner outer cylindrical walls', means to introduce the! ore to` be reduced. and a hydrocarbon gas into. the forward end of said spiral passageway under pressure, and burners in the cornbustion chamber heating the ore and hydrocarbon gas to a temperature to decompose the gas into hydrogen and carbon and partially reduce the ore with a portion of the hydrogen gas.

3. Apparatus as dened in claim 2 in which there is a second combustion chamber above the first named combustion cham-ber for preheating the ore to be reduced by burning the unused hydrogen gas.

4, Apparatus as defined in claim 3 in which there is a metal plate above the second cornbustion chamber and a conveyor above the plate for moving the ore across the top of said plate thereby causing the heat from the second combusticn chamber to be transferred to the ore.

5. Apparatus for gaseous partial reduction of iron ore comprising a combustion chamber, a rotary converter having inner` and outer cylindrical walls, and rotatably mounted in suitable bearings in said combustion chamber, there being a spiral opening defined between said cylindrical walls lor passing the ore to be reduced and a hydrocarbon gas, there being a centrally disposed opening along the longitudinal axis of the rotary converter defined by said inner cylindrical wall, a plate extending across and sealing said centrally disposed opening at the forward end thereof, there being a plurality of radial conduits rearward of said plate communicating the centrally disposed opening with the combustion chamber, a stack for the products of combustion communicating with the rear end of said centrally disposed opening, inner and outer cylinders secured to the forward end of said converter denning an annular space therebetween, there ybeing a plurality of openings at the forward side of the spiral opening communicating with said annular space for introducing ore and the hydrocarbon gas into said spiral opening, burners in the combustion chamber heating said hydrocarbon gas to a temperature to decompose the same into hydrogen and carbon and partially reduce the ore with the hydrogen means to introduce the ore and gas into said annular space, and a pipe conveying the partially reduced ore containing the carbon and spent gases from the rear end of the spiral opening to a separator for separating the spent gases from the ore and carbon.

6. Apparatus as dened in claim 5 in which the pipe conveying the partially reduced ore containing the carbon and the spent gases to the separator is tapered to approximately one-half its size at a point adjacent said separator for building up back pressure in the converter.

'7. Apparatus as dened in claim 5 in which the means to introduce the hydrocarbon gas and ore into the annular space at the forward end 7 of the rotary converter comprises a cylindrical sleeve slidably tting over the outer ends of the cylinders dem'ng said annular space, there being an opening in the sleeve for receiving the gas and ore.

8. Apparatus as defined in claim 7 in which the ore and hydrocarbon gas are introduced through a pipe which communicates with the opening in said sleeve, the ore being introduced into said pipe through a rotary pressure sealed feeder.

ERSKINE RAMSAY. ROBERT T. BAGBY.

References Cited in the file 0f this patent UNITED STATES PATENTS Number Number 8 Name Date 'I'hompson Jan. 11, 1881 Stanseld June 30, 1925 Smith May 20, 1930 Trent Dec. 20, 1932 Hougen et al. Dec. 12, 1933 Keyes Apr. 7, 1936 Mullen Apr. 3, 1938 Buchanan May 16, 1939 Jones Mar. 18, 1941 Silvasy et al Sept. 18, 1945 Lykken Mar. 14, 1950 

